Flameless barbecue grill

ABSTRACT

A grill for a barbecuing, the grill having an upper grate, wherein a grillable foodstuff may be placed thereon and a lower grate having channels which may catch juices that drips from the foodstuff. The upper grate and lower grate are positionable relative to each other, so as to vary in position between a maximally overlapped (open) grill position and a minimally overlapped (closed) grill position.

This application is a continuation of U.S. application Ser. No.11/223,076, filed on 9 Sep. 2005, which claims the benefit of U.S.Provisional Application 60/608,619 filed on 10 Sep. 2004, which '619provisional application and '076 non-provisional application are bothherein incorporated by reference in their entireties.

BACKGROUND OF THE INVENTION

The present invention relates to barbecue grills and, more particularly,barbecue grills which reduce flare ups.

Cooking meats and other foods on an open grill suffers from a basicproblem: greasy juices from meats and other grilled foods tend to dripdown into the hot coals or heated lava rock located at the bottom of thebarbecue grill causing flare ups.

Not only are flare ups a safety hazard because the flames are relativelyuncontrolled, when flare ups occur, the cooking temperature may varywildly and cause foodstuffs to cook unevenly or become burned. Forexample, meats that are being cooked may become charred in variousplaces. Charring results in a carbon-like surface to the meat which canleave an undesirable, bitter taste to the finished, cooked meat.

Therefore, what is needed is a grill for barbecuing that can control theflow of juices from the grilled food onto the coals or lava rock.

SUMMARY OF THE INVENTION

In one embodiment, a grill design is provided that prevents juices froma grilled foodstuff from dripping onto cooking coals or lava rocks thatare located at the bottom of the barbecue grill, while allowing heat torise from the hot coals and lava rocks and thereby cook the grilledfoodstuff placed on the top of the upper grate of the grill.

In another embodiment, the grill may comprise: an upper grate, where agrillable foodstuff may be placed onto, and a lower grate placed beneaththe upper grate. The lower grate can have channels for collecting juicesthat drip from the grillable foodstuff. The upper grate and lower gratemay be positionable relative to each other, so that the relativeposition may be varied between a maximally overlapped (open) grillposition and a minimally overlapped (closed) grill position.

The upper grate may be formed from elongate sections, e.g., slats orbars, that are placed in parallel and held together by at least oneconnecting piece. This connecting piece may define a periphery to theupper grate and therefore connect to the end of each elongate section.The periphery of the upper grate may be substantially rectangular inshape. Or, the connecting piece may attach to a mid-portion of eachelongate section, not the periphery of the upper grate.

Similarly, the lower grate may be formed of elongate sections, e.g.,slats, that are preferably placed substantially in parallel. Theseparallel elongate sections may be connected together by one connectingpiece or by several connecting pieces. The one connecting piece maydefine one side or part of the periphery of the lower grate and theperiphery may be substantially rectangular in shape. Alternatively, theone connecting piece may connect each elongate section in somemid-location, so that the one connecting piece does not define any ofthe periphery of the lower grate.

In some embodiments, the upper grate and/or the lower grate may bestamped from one piece. In fact, in one embodiment, the grate may havean upper grate and lower grate that are identical.

In some embodiments, the periphery of the grill may define a circular orelliptical shape. For a circular-shaped grill, the upper grate may haveelongate sections that radiate from a central axis, and is connected byat least one connecting piece. This connecting piece may also becircular and define the periphery of the upper grate. Similarly, thelower grate may have elongate sections that radiate from a central axisand have a connecting piece, e.g., a circular shaped piece that definesthe periphery.

The grill, whether substantially rectangular, circular, or having someother peripheral shape, may further include a secondary collectionchannel or gutter for collecting juices gathered by the channels of thelower grate. The secondary collection channel may have a drain fordirecting the juices into a container.

The grill may have an upper grate and a lower grate which arepositionable relative to each other.

The grill may have a “closed position”, wherein the upper grate andlower grate are positioned so that any juices falling through the uppergrate are captured by the channels in the lower grate and prevented fromfalling over the hot coals or lava rock at the bottom of the grill.Nevertheless, in this closed position, heat may rise from hot coals orlava rocks placed at the bottom of the barbecue grill and escape throughgaps between the lower grate and upper grate and thereby allow heat toreach the foodstuff placed on the upper grate.

Thus, one embodiment of the grills may have an upper grate and lowergrate that can be positionably adjusted to allow juices to fall throughthe pair of grates as with a conventional barbecue grill. The design ofthis particular embodiment of the grill thus can permit the juices tofall over the cooking coals to permit a controlled level of smoke to becreated and thereby provide a level of smoky taste to the grilled meator other foods. Additionally, however, the two grates of the grill maybe positionably adjusted to stop such juices from falling over the hotcoals or lava rock to thereby reduce or prevent uncontrolled flare ups.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of a grill comprised of an upper grateand lower grate;

FIG. 2 shows, a side cross-sectional view of the upper grate and lowergrate, while the two grates are positioned relative to each other in a“closed position” or a maximally closed position, so that juice fromfoodstuff is captured in the channels of the lower grate, although heatcan still rise through a gap in the two grates to cook the foodstuffplaced on the upper grate;

FIG. 3A shows a side, cross-sectional view of the same grate of FIG. 2,but with the two grates positioned relative to each other in the “openposition” or maximally open position, wherein juices may fall from thefoodstuff through the elongate slats, down over the hot coals or lavarock located at the bottom of the barbecue grill;

FIG. 3B shows a view of the upper grate, lower grate and a collection orsecondary channel (or gutter) that may be placed at one end of eachlower elongate section or slat to catch juices that the lower slatshaving channels has captured;

FIG. 4 shows a view of a one piece sheet that has been pressed to havepeaks and valleys (channels) which may be a precursor for manufacturinga lower or upper grate;

FIG. 5 shows, embodiments of holes that may be cut out of the precursorsheet of FIG. 4, to produce an upper or lower grate;

FIG. 6 shows, another embodiment of the holes that may be cut out of theprecursor sheet of FIG. 4, to produce an upper or lower grate; and

FIG. 7 shows, in accordance with the present invention, a grill havinglower and upper grates, with elongate sections, e.g., slats placedaxially from a central axis, wherein the width of each slat increases atthe end nearer to the outer periphery, compared to the other end of theslat.

Corresponding reference characters indicate corresponding componentsthroughout the several views of the drawings.

DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

FIG. 1 shows a top view of the grill 15, in accordance with oneembodiment of the present invention. The grill 15 can be comprised of atleast two parts, an upper grate 18 and lower grate 17. Thus, as usedherein a “grill” will refer to a two-layered device comprising an uppergrate 18 and a lower grate 17, wherein “grate” will refer herein to asingle layer of the grill. The upper grate 18 may include a plurality ofelongate sections, e.g., upper bars or slats 10 and the lower grate 17may include a plurality of elongate sections, e.g., lower bars or slats20. Each upper bar 10 of the upper grate 18 can be made with a curvatureto present a convex face on the upper surface of the upper bar 10 wherethe grilled foodstuff can be set upon. Each of the lower bars 20 of thelower grate 17 may have a longitudinal juice collection channel along apart or substantially the entire length of each lower bar 20 such thatthe juice collection channel is facing upwards towards the grilled food.As shown in FIG. 1, the lower grate 17 and each lower bar 20 may besized and dimensioned so that each lower bar 20 of the lower grate 17may be immediately positionable underneath a corresponding upper bar 10of the upper grate 18. In such relative position, the opening betweenadjacent upper bars and between adjacent lower bars coincide as to formparallel, longitudinal openings as shown in FIG. 1. In this maximallyopen grill position, it can been seen that there is a separationdistance “D” between two adjacent upper bars 10. This opening betweenupper bars 10, allows the widest grill opening in order to permit thegreatest exposure of the grilled foodstuff to the heat below the grill.

FIG. 2 provides a side view of the grill 15 of FIG. 1. As shown in FIG.2, the upper grate 18 and lower grate 17 are shown. Each of the lowerbars 20 can be formed with a channel having a shape 90 to catch greasyjuices 95 that come from the foodstuff 50, such as a meat. The lowergrate channel 90 may have a cross-sectional configuration such as a U ora V or any other form that can catch juices 95. The upper bars 10 ofupper grate 18 may have a cross-sectional configuration which is anupside down U as shown in FIG. 2 or other forms such as an upside V, orforms such as a circle, ellipse, square, rectangle or anothercross-sectional form that can support foodstuff 50 placed on top of theupper bar 10. Foodstuff 50 is shown on top of upper bars 18 of uppergrate 18. The foodstuff 50 may be any known grillable foods, includingwithout limitation, meats such as steak, poultry, fish or pork. Theupper grate 18 with a plurality of upper bars 10 is shown positioned sothat each opening 60 between adjacent upper bars 10 is entirely coveredunderneath by a lower bar 20 with respect to a downward line-of-sight.With the lower grate 17, positioned thusly, juices 95 such as greasefrom food stuff 50, can be caught in juice collection channel 90 of theeach lower bar 20 of lower grate 17. The lower bars 20 may be inclinedslightly to one end as to cause to juices 95 to flow to one end of thelower bars 20 at one end, where it can empty into another collectionchannel (not shown). The collection channel may be perpendicular and maybe placed so as to catch juices from each of the lower bars 20. WhileFIG. 2 shows an embodiment of a grill, in accordance with invention, ina maximally covered position, importantly, there is still an opening orgap 70 between each the upper bars 10 and lower bars 20. This opening orgap is sufficient to allow heat 80 to rise from coals or lava rock 100and to go escape through between upper grate 10 and lower grate 20, eventhough the lower grate 17 and upper grate 18 are in a maximally coveredrelative position. Thus, cooking of the foodstuff 50 can continue tooccur even in this maximally covered grill position because gap 70between the lower grate 17 and upper grate 18 permits heat 80 emanatingfrom coals or lava rock 100 to thereby rise through the grill 15.

FIG. 3A, provides a side view of the grate shown in FIGS. 1 and 2,however, with the grill 15 in the minimally covered position. Here, thelower grate 17 can be horizontally displaced so that each lower bar 20is placed directly underneath a corresponding upper bar 10 of uppergrate 18. In this minimally covered grill position, the heat 80emanating from hot coal or lava rock 100 can rise upwards directlythrough the opening 60 between two adjacent upper grates 10 and twoadjacent lower grates 20 so that the rising heat 80 can cook foodstuff50. In this minimally covered position, juices 95 from foodstuff 50 donot collect in the channels of the lower bars 20 but, instead, can fallfreely down towards the bottom placed coals 100, so that the grill 15functions similarly to a conventional grill.

FIGS. 1, 2 and 3A illustrate the features of an embodiment of thepresent invention. The grate, in accordance with one embodiment of thepresent invention comprises: (a) an upper grate 18 and (b) a lower grate17. Preferably the separation distance between the upper grate 18 andlower grate 17 is less than about 1 inch and more preferably less thanabout 0.5 inches. The lower grate 17 has a juice collection channel thatcan effectively capture juices 95 when the lower grate 17 is positionedwith respect to the upper grate 18 so that the grill 15 is in amaximally or partially closed position. The lower grate 17, relative tothe upper grate 18, can be movable from between a maximal covered(relatively closed) position as shown in FIG. 2, wherein the juices 95will be captured and a minimally covered (open) position. In addition,the upper grate 18 and lower grate 17 must be positionable relative toeach other so that even in the so-called maximally covered position,there is a space 70 between the upper bars 10 and lower bars 20, whichspace 70 allows heat 80 to escape through the grill 15, so that cookingof foodstuff 50 can take place even in this maximally covered (closed)grill position. The upper bars 10 may be shaped in many differentcross-sectional shapes, e.g., square rods or bars or round or ellipticalshaped rods.

However, the relationship between the opening “D” that is made betweenadjacent upper bars 10 dictates to some extent the width D1, which isthe width of the lower bars 20, and also D2, which is the separationwidth between two adjacent lower bars 20. It can be seen that D1+D2cannot exceed D4+D, where D, D1, D2 and D4 are non-zero values. D1,however, must be greater than D. In a preferred embodiment of thepresent invention, D1 is slightly less than D4, thereby allowing atleast some of the lower bars 20 of lower grate 17 to “hide” completelyunderneath the corresponding upper bars 10 in the maximally open grillposition. In this maximally open grill position, the grill of thepresent invention largely mimics the operation of a conventional grill.Although it is preferred that D1 is slightly smaller than D4, it is,however, possible that D1 may also be larger than D4 and, nevertheless,provide a functional grill in accordance with the present invention.

FIG. 3B shows an embodiment that includes the grill design shown inFIGS. 1, 2 and 3A. A runoff gutter 140 may be included to the grilldesign 15. The runoff gutter (or secondary trough) 140 may be inclinedto one end where a receptacle (not shown) may capture the excess run-offgrease. Alternatively, the runoff gutter may have a drain 130 at somepoint which can be used to collect the runoff grease. If the drain 130is placed at some mid-point of the runoff gutter, both sides of therunoff gutter around the drain 130 must be slightly inclined as togravitationally urge the grease to enter the drain 130. The runoffgutter may or may not be attached to the lower grate 20.

In operation, the grill 15 (Shown in FIGS. 1, 2 and 3) can be used inthe following manner. The coals 100 may be heated. For instance, if thebarbecue grill uses lava rocks 100, they may be heated by lighting thegas supplied. The lower grate 18 and upper grate 17 of grill 15 can bepositioned for minimal grill covering (maximal flow of heat through thegrill) as shown in FIG. 1 and FIG. 3A. Foodstuff, e.g., a steak 50, isplaced on top of the upper grate 18. Over some time, grease 95 fromsteak 50 will begin to melt and fall through the opening 60 betweenupper grates 10 and lower grates 20. The flow of grease onto lava rockor coals 100 can cause small grease fires to flare up. When flare upsbegin to occur, the lower grate 18 may be moved relative to the uppergrate 17 to a maximally covered position, as shown in FIG. 2. Thisrelative position change will have two immediate effects: (a) it willprevent additional juices 95 from dropping over the hot lava rock orcoals 100 and thereby reduce the fuel for continuing flare-ups and (b)the present flare-up will be reduced in intensity since the grateopening 70 will be reduced from which the heat and flame can escape. Asa result, food stuff 50 will not become undesirably charred, as theflame which reaches the foodstuff 50 will be immediately reduced inintensity. Moreover, the grill 15 can advantageously reduce theintensity of the heat escaping through the two layers of the grill 15and prevent dangerous and undesirable flare-ups fueled by greasedripping onto hot lava rocks or coals 100.

Thus, the grill 15 offers increased safety to the user of the grill bycontrolling flare-ups. In addition, the grill can be used to control theheat applied to the foodstuff 50 by adjusting the opening 70 betweenupper grate 18 and lower grate 17, by moving either the upper bar 10while the lower bar 20 remains stationary or, alternatively, moving thelower bar 20 relative to the upper bar 10.

In another example use of the present grill 15, if regular coals 100 areused, the goals can be ignited using lighting fluid. The grill can bemaximally closed or open to control the initial flame over the coalslighted by lighting fluid. Once flames have died down and the coals areglowing, the grilled foodstuff 50 may be placed over the upper grate 18.Advantageously, the heat 80 that is applied through the grill 15 to thefoodstuff 50 can be controlled by adjusting the opening 70 formedbetween upper bars 10 and lower bars 20, relative to each other.

Various embodiments of the grill are conceivable and come within thepurview of the present invention. For example, the upper bars 10 may allbe linked together by at least one connecting piece. Connecting piecesmay be inserted into insertions 30 and 31 (FIG. 1). A first connectingpiece can be attached at all insertions 31 and a second connecting piececan be attached at all insertions 30, thereby linking each longitudinalupper bar 10, into one unit upper grate 18. The connecting pieces may bespot welded together. A similar connecting piece or pieces may be usedto form a unit lower grate 17 holding each lower bar 20 together.

As shown in FIG. 4, the upper and lower grates may be initially formedfrom a one-piece, precursor metal piece 200 that is stamped to formundulations (peaks and troughs). Then, as shown in FIG. 5 and FIG. 6,various configurations of longitudinal openings may be machine stampedin one step to create the opening 110 or opening 120 that is necessaryin both the upper grate 18 and lower grate 17. FIG. 5 shows the uppergrate 18 with longitudinal holes 110 that may be stamped out one hole ata time or all at once for the entire upper grate 10. Alternatively, theupper grate 18 may have a plurality of smaller holes 120 along alongitudinal trough. The lower grate 20 may have corresponding holes andchannels to permit a maximally open position and closed position.

FIG. 6 shows one embodiment of the lower grate 17 with severallongitudinal holes 115 along one dimension of the lower grate 17. Thelower grate 17 may optionally have smaller longitudinal holes 122 alongone dimension of the grate 17. Lower grate 17 must have juice collectionchannels located between adjacent holes 115. Stamping the upper grate 18and lower grate 17 can increase the speed at which the grill may bemanufactured and reduce the overall cost.

As shown in FIG. 7, one embodiment of the present invention may beconfigured into a round grill 250. The same elements of the grill arepresent. That is the grill 250, although intended for a round grill, hasan upper grate with upper elongate sections or slats 10′ and lower gratewith lower elongate sections or slats 20′. The upper grate and lowergrate preferably has a separation distance that is less than about 1inch and more preferably less than about 0.5 inches. The upper slats 10′and lower slats 20′ are configured and sized to be positionable relativeto each other and to provide a minimally overlapped (closed) positionedand a maximally overlapped position (opened) grill position. The uppergrate and lower grate may have at least a connecting piece that holdseach slat in proper spacing. The connecting piece may be attachedanywhere along the length of the slats 10′ and 20′, joining all thelower slats to form the lower grate or joining all the upper slats toform the upper grate. Both the slats of the upper grate and lower gratemay be shaped to be broader at the periphery and narrower towards theaxis of the circular grates, e.g., as in a very narrow pie shape or avery narrow pizza cut. In the closed grill position, the grease ispicked up by the channel or trough located in the slats of the lowergrate. In the maximally overlapped, opened grill position, correspondinglower slats 20′ “hide” directly underneath the corresponding upper slat10′.

A runoff gutter may be placed around the outer periphery of the grill.The channeled, lower slats 20′ of the lower grate may be inclined towardthe periphery, where the runoff gutter may be placed around the outerperiphery of the grill. The runoff gutter may have a drain which isplaced slightly lower than the other portions of the runoff gutter toguide the grease down into the drain and into a collection container.Alternatively, a runoff drain may be placed centrally under the lowergrill collecting grease from all of the slats of the lower grate and thegrease may run into a collecting container.

To construct the circular grill, the lower grate may be first stampedfrom a one-piece metal piece to provide the appropriately spacedundulations (forming channels). The upper grate may be made from asingle, flat sheet, or it may be may, like the lower grate, firststamped to have channels, and then stamped again to create narrow,pie-shaped holes, radiating axially outward from the center. Then,elongated holes may be stamped out in pie-shaped pieces, but with theperipheral (circumferential) outline intact. This simultaneously formsthe necessary elongated holes and connection means to keep the channeledslats spaced appropriately apart.

It may be appreciated that there may be a wide variety of methods oflinking, connecting and suspending the upper grate 18, 18′ appropriatelywith the lower grate 17, 17′. The method of suspension will not belimited to the embodiments shown and it will be understood that anygrill, having at least one positionable upper and/or lower grate, withrespect to each other, defining a maximally overlapped (open) positionand minimally overlapped (closed) position, is within the conceivedboundaries of the present invention.

The invention has been described in terms of exemplary embodiments. Theinvention, however, is not limited to the embodiments depicted anddescribed and it is contemplated that other embodiments, which may bereadily devised by persons of ordinary skill in the art, as described bythe claims below, are within the scope of the invention.

1. A grill for a barbecuing, comprising: an upper grate, wherein agrillable foodstuff may be placed onto; and a lower grate, placedbeneath the upper grate, wherein the lower grate has channels forcollecting juices from the grillable foodstuff, wherein the upper grateand lower grate are positionable relative to each other, such that therelative position may be varied between a maximally overlapped, open,grill position and a minimally overlapped, closed, grill position; andwherein the upper grate and lower grate are separated by a distance thatis less than about 1.0 inch.
 2. The grill of claim 1, wherein the uppergrate is formed from elongate sections, and wherein adjacent elongatesections are connected by at least one connecting piece.
 3. The grill ofclaim 2, wherein the at least one connecting piece is a piece that isnot located at the periphery of the upper grate.
 4. The grill of claim2, wherein the at least one connecting piece is a piece that is placedaround the periphery of the upper grate.
 5. The grill of claim 2,wherein upper grate has a periphery that is substantially a rectangularshape.
 6. The grill of claim 1, wherein the lower grate is formed fromelongate sections, and wherein adjacent elongate sections are connectedby at least one connecting piece.
 7. The grill of claim 6, wherein theat least one connecting piece is a piece that is not located at theperiphery of the lower grate.
 8. The grill of claim 6, wherein the atleast one connecting piece is a piece that is placed around theperiphery of the lower grate.
 9. The grill of claim 1, wherein the uppergrate and lower grate are separated by a distance that is less thanabout 0.5 inches.
 10. The grill of claim 1, wherein the upper grate isstamped from a one-piece metal.
 11. The grill of claim 1, wherein thelower grate is stamped from a one-piece metal.
 12. The grill of claim 1,wherein the lower grate has a periphery that is substantially a circularshape.
 13. The grill of claim 1, wherein the lower grate has a peripherythat is substantially an elliptical shape.
 14. The grill of claim 1,further comprising: a secondary collection channel positioned andconfigured to permit flow of juices from the channels in the lower grateto the secondary collection channel.
 15. The grill of claim 1, whereinthe secondary channel has a drain, wherein juices captured by thecollection channel flow into the drain.
 16. A grill for barbecuing,comprising: an upper grate, wherein a grillable foodstuff may be placedonto; and a lower grate, wherein the grate has channels for collectingjuices, wherein the upper grate and lower grate are positionablerelative to each other between a maximally overlapped, open, grillposition and a minimally overlapped, closed, grill position, wherein theupper and lower grates are configured to fit inside the barbecue grillwhich is substantially circular; and wherein the upper grate and lowergrate is separated by less than about 1.0 inch.
 17. The grill of claim16, wherein the upper grate is formed from slat sections that radiatefrom a central axis, and is connected by at least one connecting piece.18. The grill of claim 17, wherein the at least one connecting piece isa piece that is placed around the periphery of the upper grate.
 19. Thegrill of claim 16, wherein the lower grate is stamped from a one-piecemetal.
 20. The grill of claim 16, further comprising: a secondarycollection channel positioned and configured to permit flow of juicesfrom the channels in the lower grate to the secondary collectionchannel.